JCB JS160W AUTO TIER III WHEELED EXCAVATOR Service Repair Manual SN01451000 to 01451999

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Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9803/6590-4 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual JS130W, JS145W, JS160W, JS175W Section 1 - General Information Section 2 - Care & Safety Section 3 - Maintenance Section B - Body & Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section K - Engine
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Transcript of JCB JS160W AUTO TIER III WHEELED EXCAVATOR Service Repair Manual SN01451000 to 01451999

  • Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

    World ClassCustomer Support

    9803/6590-4Publication No.

    Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

    Service Manual

    JS130W, JS145W, JS160W, JS175WSection 1 - General Information

    Section 2 - Care & SafetySection 3 - Maintenance

    Section B - Body & FrameworkSection C - ElectricsSection D - Controls

    Section E - HydraulicsSection F - Transmission

    Section K - Engine

  • Page No.Contents

    Section 1 - General Information

    1-i 1-i

    IntroductionAbout this Manual ...................................................................................... 1-1Identifing Your Machine ............................................................................. 1-3

    Torque SettingsZinc Plated Fasteners and Dacromet Fasteners ....................................... 1-5Hydraulic Connections ............................................................................... 1-9

    Service ToolsNumerical List .......................................................................................... 1-13Tool Detail Reference .............................................................................. 1-16

    Service ConsumablesSealing and Retaining Compounds ......................................................... 1-35

    Terms and DefinitionsColour Coding .......................................................................................... 1-37

  • Section 1 - General Information

    1-1 1-19803-6590-3

    IntroductionAbout this Manual

    Machine Model and Serial Number

    This manual provides information for the followingmodel(s) in the JCB machine range:

    JCB JS130W from serial number 01060300 to 01060999.

    JCB JS145W from serial number 01314300 to 01314599.

    JCB JS145W from serial number 01458000 to 01458999.

    JCB JS145W from serial number 01613000 to 1613999.

    JCB JS160W from serial number 01421600 to 01421799.

    JCB JS160W from serial number 01451000 to 01451999.

    JCB JS175W from serial number 01505100 to 01505284.

    JCB JS175W from serial number 01505286 to 01505499.

    Using the Service ManualT11-004

    This publication is designed for the benefit of JCBDistributor Service Engineers who are receiving, or havereceived, training by JCB Technical Training Department.

    These personnel should have a sound knowledge ofworkshop practice, safety procedures, and generaltechniques associated with the maintenance and repair ofhydraulic earthmoving equipment.

    The illustrations in this publication are for guidance only.Where the machines differ, the text and/or the illustrationwill specify.

    General warnings in Section 2 are repeated throughout themanual, as well as specific warnings. Read all safetystatements regularly, so you do not forget them.

    Renewal of oil seals, gaskets, etc., and any componentshowing obvious signs of wear or damage is expected asa matter of course. It is expected that components will becleaned and lubricated where appropriate, and that anyopened hose or pipe connections will be blanked toprevent excessive loss of hydraulic fluid and ingress of dirt.

    Where a torque setting is given as a single figure it may bevaried by plus or minus 3%. Torque figures indicated arefor dry threads, hence for lubricated threads may bereduced by one third.

    The manufacturer's policy is one of continuousimprovement. The right to change the specification of themachine without notice is reserved. No responsibility willbe accepted for discrepancies which may occur betweenspecifications of the machine and the descriptionscontained in this publication.

    Finally, please remember above all else safety must comefirst!

    Section NumberingT11-005

    The manual is compiled in sections, the first three arenumbered and contain information as follows:

    The remaining sections are alphabetically coded and dealwith Dismantling, Overhaul etc. of specific components, forexample:

    Section contents, technical data, circuit descriptions,operation descriptions etc. are inserted at the beginning ofeach alphabetically coded section.

    1 General Information - includes torque settings and service tools.

    2 Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.

    3 Maintenance - includes service schedules and recommended lubricants for all the machine.

    A AttachmentsB Body and Framework, etc.

  • Section 1 - General InformationIntroduction

    About this Manual

    1-2 1-29803-6590-3

    Left Side, Right Side

    In this manual, 'left' A and 'right' B mean your left and rightwhen you are seated correctly in the machine.

    Cross ReferencesT1-004_2

    In this publication, page cross references are made bypresenting the subject title printed in bold, italic andunderlined. It is preceeded by the 'go to' symbol. Thenumber of the page upon which the subject begins, isindicated within the brackets. For example: K CrossReferences ( T 1-2).

    A

    B

  • Section 1 - General InformationIntroduction

    Identifing Your Machine

    1-3 1-39803-6590-3

    Identifing Your Machine

    Machine Identification Plate

    Your machine has a data plate located on the outside thecab as shown at A. The machine serial number is inscribedat B which is the base plate of the rear frame.

    Fig 1.

    Fig 2.

    Typical Product Identification Number (PIN)

    1 World Manufacturer Identification (JCB)

    2 Machine Type and Model (JW175 = JS175 Wheeled)

    3 Randomly generated check letter.

    4 Machine Serial Number (01018354)

    1 2 3 4JCB JW175 C 01018354

  • Section 1 - General InformationIntroduction

    Identifing Your Machine

    1-4 1-49803-6590-3

    Component Identification Plates

    Typical Engine Identification Number

    If the engine is replaced by a new one, the data plate serialnumber will be wrong. Either stamp the new number on theplate or stamp out the old one. This will prevent the wrongnumber being quoted when you order replacement parts.

    The engine number is stamped at A.

    Fig 3. 4JJ

    Fig 4. 4HK

    Axle Serial Plate

    The axle serial number is stamped on a plate D mountedto the rear face of the axle.

    When replacement parts are required, always ensure thatthe correct parts are obtained, e.g. in the case of gearreplacements, always check the part number stamped onthe gear, and the number of teeth.

    When ordering replacement parts, quote the details on theserial plate as shown.

    Fig 5.

    A

    A

  • Section 1 - General InformationTorque Settings

    Zinc Plated Fasteners and Dacromet Fasteners

    1-5 1-59803-6590-3

    Torque SettingsZinc Plated Fasteners and Dacromet Fasteners

    T11-002

    Introduction

    Some external fasteners on JCB machines aremanufactured using an improved type of corrosionresistant finish. This type of finish is called Dacromet andreplaces the original Zinc and Yellow Plating used onearlier machines.

    The two types of fasteners can be readily identified bycolour and part number suffix. K Table 1. Fastener Types( T 1-5).

    Table 1. Fastener Types

    Note: As the Dacromet fasteners have a lower torquesetting than the Zinc and Yellow fasteners, the torquefigures used must be relevant to the type of fastener.

    Note: A Dacromet bolt should not be used in conjunctionwith a Zinc or Yellow plated nut, as this could change thetorque characteristics of the torque setting further. For thesame reason, a Dacromet nut should not be used with aZinc or Yellow plated bolt.

    Note: All bolts used on JCB machines are high tensile andmust not be replaced by bolts of a lesser tensilespecification.

    Note: Dacromet bolts, due to their high corrosionresistance are used in areas where rust could occur.Dacromet bolts are only used for external applications.They are not used in applications such as gearbox orengine joint seams or internal applications.

    Bolts and Screws

    Use the following torque setting tables only where notorque setting is specified in the text.

    Note: Dacromet fasteners are lubricated as part of theplating process, do not lubricate.

    Torque settings are given for the following conditions:

    Condition 1

    – Un-lubricated fasteners– Zinc fasteners– Yellow plated fasteners

    Condition 2

    – Zinc flake (Dacromet) fasteners– Lubricated zinc and yellow plated fasteners– Where there is a natural lubrication. For example,

    cast iron components

    Verbus Ripp Bolts

    Fig 1.

    Torque settings for these bolts are determined by theapplication. Refer to the relevant procedure for therequired settings.

    Fastener Type

    Colour Part No. Suffix

    Zinc and Yellow

    Golden finish 'Z' (e.g. 1315/3712Z)

    Dacromet Mottled silver finish 'D' (e.g. 1315/3712D)

  • Section 1 - General InformationTorque Settings

    Zinc Plated Fasteners and Dacromet Fasteners

    1-6 1-69803-6590-3

    Table 2. Torque Settings - UNF Grade 'S' Fasteners

    Table 3. Torque Settings - Metric Grade 8.8 Fasteners

    Bolt Size Hexagon (A/F) Condition 1 Condition 2in. mm in. Nm kgf m lbf ft Nm kgf m lbf ft1/4 6.3 7/16 11.2 1.1 8.3 10.0 1.0 7.4

    5/16 7.9 1/2 22.3 2.3 16.4 20.0 2.0 14.7

    3/8 9.5 9/16 40.0 4.1 29.5 36.0 3.7 26.5

    7/16 11.1 5/8 64.0 6.5 47.2 57.0 5.8 42.0

    1/2 12.7 3/4 98.00 10.0 72.3 88.0 9.0 64.9

    9/16 14.3 13/16 140.0 14.3 103.2 126.0 12.8 92.9

    5/8 15.9 15/16 196.0 20.0 144.6 177.0 18.0 130.5

    3/4 19.0 1 1/8 343.0 35.0 253.0 309.0 31.5 227.9

    7/8 22.2 1 15/16 547.0 55.8 403.4 492.0 50.2 362.9

    1 25.4 1 1/2 814.0 83.0 600.4 732.0 74.6 539.9

    1 1/8 31.7 1 7/8 1181.0 120.4 871.1 1063.0 108.4 784.0

    1 1/4 38.1 2 1/4 1646.0 167.8 1214.0 1481.0 151.0 1092.3

    Bolt Size Hexagon (A/F) Condition 1 Condition 2ISO Metric

    Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ftM5 5 8 5.8 0.6 4.3 5.2 0.5 3.8

    M6 6 10 9.9 1.0 7.3 9.0 0.9 6.6

    M8 8 13 24.0 2.4 17.7 22.0 2.2 16.2

    M10 10 17 47.0 4.8 34.7 43.0 4.4 31.7

    M12 12 19 83.0 8.5 61.2 74.0 7.5 54.6

    M16 16 24 205.0 20.9 151.2 184.0 18.8 135.7

    M20 20 30 400.0 40.8 295.0 360.0 36.7 265.5

    M24 24 36 690.0 70.4 508.9 621.0 63.3 458.0

    M30 30 46 1372.0 139.9 1011.9 1235.0 125.9 910.9

    M36 36 55 2399.0 244.6 1769.4 2159.0 220.0 1592.4

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  • Section 1 - General InformationTorque Settings

    Zinc Plated Fasteners and Dacromet Fasteners

    1-7 1-79803-6590-3

    Table 4. Metric Grade 10.9 Fasteners

    Table 5. Metric Grade 12.9 Fasteners

    Bolt Size Hexagon (A/F) Condition 1 Condition 2ISO Metric

    Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ftM5 5 8 8.1 0.8 6.0 7.3 0.7 5.4

    M6 6 10 13.9 1.4 10.2 12.5 1.3 9.2

    M8 8 13 34.0 3.5 25.0 30.0 3.0 22.1

    M10 10 17 67.0 6.8 49.4 60.0 6.1 44.2

    M12 12 19 116.0 11.8 85.5 104.0 10.6 76.7

    M16 16 24 288.0 29.4 212.4 259.0 26.4 191.0

    M20 20 30 562.0 57.3 414.5 506.0 51.6 373.2

    M24 24 36 971.0 99.0 716.9 874.0 89.1 644.6

    M30 30 46 1930.0 196.8 1423.5 1737.0 177.1 1281.1

    M36 36 55 3374.0 344.0 2488.5 3036.0 309.6 2239.2

    Bolt Size Hexagon (A/F) Condition 1 Condition 2ISO Metric

    Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ftM5 5 8 9.8 1.0 7.2 8.8 0.9 6.5

    M6 6 10 16.6 1.7 12.2 15.0 1.5 11.1

    M8 8 13 40.0 4.1 29.5 36.0 3.7 26.5

    M10 10 17 80.0 8.1 59.0 72.0 7.3 53.1

    M12 12 19 139.0 14.2 102.5 125.0 12.7 92.2

    M16 16 24 345.0 35.2 254.4 311.0 31.7 229.4

    M20 20 30 674.0 68.7 497.1 607.0 61.9 447.7

    M24 24 36 1165.0 118.8 859.2 1048.0 106.9 773.0

    M30 30 46 2316.0 236.2 1708.2 2084.0 212.5 1537.1

    M36 36 55 4049.0 412.9 2986.4 3644.0 371.6 2687.7

  • Section 1 - General InformationTorque Settings

    Zinc Plated Fasteners and Dacromet Fasteners

    1-8 1-89803-6590-3

    Table 6. Torque Settings - Rivet Nut Bolts/Screws

    Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc)

    Bolt Size

    Nm kgf m lbf ftISO Metric

    Thread mmM3 3 1.2 0.1 0.9

    M4 4 3.0 0.3 2.0

    M5 5 6.0 0.6 4.5

    M6 6 10.0 1.0 7.5

    M8 8 24.0 2.5 18.0

    M10 10 48.0 4.9 35.5

    M12 12 82.0 8.4 60.5

    Bolt Size

    Nm kgf m lbf ftISO Metric

    ThreadM3 2.0 0.2 1.5

    M4 6.0 0.6 4.5

    M5 11.0 1.1 8.0

    M6 19.0 1.9 14.0

    M8 46.0 4.7 34.0

    M10 91.0 9.3 67.0

    M12 159.0 16.2 117.0

    M16 395.0 40.0 292.0

    M18 550.0 56.0 406.0

    M20 770.0 79.0 568.0

    M24 1332.0 136.0 983.0

  • Section 1 - General InformationTorque Settings

    Hydraulic Connections

    1-9 1-99803-6590-3

    Hydraulic ConnectionsT11-003

    'O' Ring Face Seal System

    Adaptors Screwed into Valve Blocks

    Adaptor screwed into valve blocks, seal onto an 'O' ringwhich is compressed into a 45° seat machined into theface of the tapped port.

    Table 8. Torque Settings - BSP Adaptors

    Table 9. Torque Settings - SAE Connections

    BSP Adaptor Size

    Hexagon (A/F)

    Nm kgf m lbf ftin. mm1/4 19.0 18.0 1.8 13.0

    3/8 22.0 31.0 3.2 23.0

    1/2 27.0 49.0 5.0 36.0

    5/8 30.0 60.0 6.1 44.0

    3/4 32.0 81.0 8.2 60.0

    1 38.0 129.0 13.1 95.0

    1 1/4 50.0 206.0 21.0 152.0

    SAE Tube Size

    SAE Port Thread Size

    Hexagon (A/F)Nm kgf m lbf ftmm

    4 7/16 - 20 15.9 20.0 - 28.0 2.0 - 2.8 16.5 - 18.5

    6 9/16 - 18 19.1 46.0 - 54.0 4.7 - 5.5 34.0 - 40.0

    8 3/4 - 16 22.2 95.0 - 105.0 9.7 - 10.7 69.0 - 77.0

    10 7/8 - 14 27.0 130.0 - 140.0 13.2 - 14.3 96.0 - 104.0

    12 1 1/16 - 12 31.8 190.0 - 210.0 19.4 - 21.4 141.0 - 155.0

    16 1 5/16 - 12 38.1 290.0 - 310.0 29.6 - 31.6 216.0 - 230.0

    20 1 5/8 47.6 280.0 - 380.0 28.5 - 38.7 210.0 - 280.0

  • Section 1 - General InformationTorque Settings

    Hydraulic Connections

    1-10 1-109803-6590-3

    Hoses Screwed into Adaptors

    Fig 2.

    Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring2-C which is compressed into a 45° seat machined into theface of the adaptor port.

    Note: Dimension 2-D will vary depending upon the torqueapplied.

    Table 10. BSP Hose - Torque SettingsBSP Hose Size Hexagon (A/F)

    Nm kgf m lbf ftin. mm1/8 14.0 14.0 - 16.00 1.4 - 1.6 10.3 - 11.8

    1/4 19.0 24.0 - 27.0 2.4 - 2.7 17.7 - 19.9

    3/8 22.0 33.0 - 40.0 3.4 - 4.1 24.3 - 29.5

    1/2 27.0 44.0 - 50.0 4.5 - 5.1 32.4 - 36.9

    5/8 30.0 58.0 - 65.0 5.9 - 6.6 42.8 - 47.9

    3/4 32.0 84.0 - 92.0 8.6 - 9.4 61.9 - 67.8

    1 38.0 115.0 - 126.0 11.7 - 12.8 84.8 - 92.9

    1 1/4 50.0 189.0 - 200.0 19.3 - 20.4 139.4 - 147.5

    1 1/2 55.0 244.0 - 260.0 24.9 - 26.5 180.0 - 191.8

  • Section 1 - General InformationTorque Settings

    Hydraulic Connections

    1-11 1-119803-6590-3

    Adaptors into Component Connections with Bonded Washers

    Table 11. BSP Adaptors with Bonded Washers - Torque SettingsBSP Size

    Nm kgf m lbf ftin.1/8 20.0 2.1 15.0

    1/4 34.0 3.4 25.0

    3/8 75.0 7.6 55.0

    1/2 102.0 10.3 75.0

    5/8 122.0 12.4 90.0

    3/4 183.0 18.7 135.0

    1 203.0 20.7 150.0

    1 1/4 305.0 31.0 225.0

    1 1/2 305.0 31.0 225.0

    Button2: